Semiconductor device having a shaped epitaxial region

ABSTRACT

A source/drain region of a semiconductor device is formed using an epitaxial growth process. In an embodiment a first step comprises forming a bulk region of the source/drain region using a first precursor, a second precursor, and an etching precursor. A second step comprises cleaning the bulk region with the etchant along with introducing a shaping dopant to the bulk region in order to modify the crystalline structure of the exposed surfaces. A third step comprises forming a finishing region of the source/drain region using the first precursor, the second precursor, and the etching precursor.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a division of U.S. patent application Ser. No.16/049,518, filed on Jul. 30, 2018 and entitled “Semiconductor DeviceHaving a Shaped Epitaxial Region,” which application is a division ofU.S. patent application Ser. No. 15/284,101, filed on Oct. 3, 2016 andentitled “Semiconductor Device and Method,” now U.S. Pat. No. 10,164,098issued on Dec. 25, 2018, which application claims the benefit of U.S.Provisional Application No. 62/357,161, filed on Jun. 30, 2016 andentitled “Semiconductor Device and Method,” which applications areincorporated herein by reference.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications,such as, for example, personal computers, cell phones, digital cameras,and other electronic equipment. Semiconductor devices are typicallyfabricated by sequentially depositing insulating or dielectric layers,conductive layers, and semiconductor layers of material over asemiconductor substrate, and patterning the various material layersusing lithography to form circuit components and elements thereon.

The semiconductor industry continues to improve the integration densityof various electronic components (e.g., transistors, diodes, resistors,capacitors, etc.) by continual reductions in minimum feature size, whichallow more components to be integrated into a given area. However, asthe minimum features sizes are reduced, additional problems arise thatshould be addressed.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 illustrates fins for a FinFET transistor in accordance with someembodiments.

FIG. 2 illustrates a removal of a portion of the fins in accordance withsome embodiments.

FIGS. 3A-3F illustrate a regrowth of source/drain regions within anepitaxial growth chamber in accordance with some embodiments.

FIGS. 4A-4B illustrates etch rate data for silicon and for silicon withgermanium incorporated in accordance with some embodiments.

FIGS. 5A-5B illustrate concentration data of a source/drain region inaccordance with some embodiments.

FIG. 6 illustrates a summary of a process flow for the regrowth of thesource/drain regions in accordance with some embodiments.

FIGS. 7A-7C illustrates another embodiment which uses different depthsfor interfin isolation regions and intrafin isolation regions inaccordance with some embodiments.

FIG. 8 illustrates another embodiment in which the source/drain regionsare utilized within a planar transistor in accordance with someembodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the invention. Specificexamples of components and arrangements are described below to simplifythe present disclosure. These are, of course, merely examples and arenot intended to be limiting. For example, the formation of a firstfeature over or on a second feature in the description that follows mayinclude embodiments in which the first and second features are formed indirect contact, and may also include embodiments in which additionalfeatures may be formed between the first and second features, such thatthe first and second features may not be in direct contact. In addition,the present disclosure may repeat reference numerals and/or letters inthe various examples. This repetition is for the purpose of simplicityand clarity and does not in itself dictate a relationship between thevarious embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

With reference now to FIG. 1, there is shown a substrate 101 with firsttrenches 103 formed therein. The substrate 101 may be a siliconsubstrate, although other substrates, such as semiconductor-on-insulator(SOI), strained SOI, and silicon germanium on insulator, could be used.The substrate 101 may be a p-type semiconductor, although in otherembodiments, it could be an n-type semiconductor.

The first trenches 103 may be formed as an initial step in the eventualformation of first isolation regions 107. The first trenches 103 may beformed using a masking layer (not separately illustrated in FIG. 1)along with a suitable etching process. For example, the masking layermay be a hardmask comprising silicon nitride formed through a processsuch as chemical vapor deposition (CVD), although other materials, suchas oxides, oxynitrides, silicon carbide, combinations of these, or thelike, and other processes, such as plasma enhanced chemical vapordeposition (PECVD), low pressure chemical vapor deposition (LPCVD), oreven silicon oxide formation followed by nitridation, may be utilized.Once formed, the masking layer may be patterned through a suitablephotolithographic process to expose those portions of the substrate 101that will be removed to form the first trenches 103.

As one of skill in the art will recognize, however, the processes andmaterials described above to form the masking layer are not the onlymethod that may be used to protect portions of the substrate 101 whileexposing other portions of the substrate 101 for the formation of thefirst trenches 103. Any suitable process, such as a patterned anddeveloped photoresist, may be utilized to expose portions of thesubstrate 101 to be removed to form the first trenches 103. All suchmethods are fully intended to be included in the scope of the presentembodiments.

Once a masking layer has been formed and patterned, the first trenches103 are formed in the substrate 101. The exposed substrate 101 may beremoved through a suitable process such as reactive ion etching (RIE) inorder to form the first trenches 103 in the substrate 101, although anysuitable process may be used. In an embodiment, the first trenches 103may be formed to have a first depth of less than about 5,000 Å from thesurface of the substrate 101, such as about 2,500 Å.

However, as one of ordinary skill in the art will recognize, the processdescribed above to form the first trenches 103 is merely one potentialprocess, and is not meant to be the only embodiment. Rather, anysuitable process through which the first trenches 103 may be formed maybe utilized and any suitable process, including any number of maskingand removal steps may be used.

In addition to forming the first trenches 103, the masking and etchingprocess additionally forms fins 105 from those portions of the substrate101 that remain unremoved. For convenience the fins 105 have beenillustrated in the figures as being separated from the substrate 101 bya dashed line, although a physical indication of the separation may ormay not be present. These fins 105 may be used, as discussed below, toform the channel region of multiple-gate FinFET transistors. While FIG.1 only illustrates three fins 105 formed from the substrate 101, anynumber of fins 105 may be utilized.

The fins 105 may be formed such that they have a first width W₁ at thesurface of the substrate 101 of between about 5 nm and about 80 nm, suchas about 30 nm. Additionally, the fins 105 may be spaced apart from eachother by a first distance D₁ of between about 10 nm and about 100 nm,such as about 50 nm. By spacing the fins 105 in such a fashion, the fins105 may each form a separate channel region while still being closeenough to share a common gate (discussed further below).

Once the first trenches 103 and the fins 105 have been formed, the firsttrenches 103 may be filled with a dielectric material and the dielectricmaterial may be recessed within the first trenches 103 to form the firstisolation regions 107. The dielectric material may be an oxide material,a high-density plasma (HDP) oxide, or the like. The dielectric materialmay be formed, after an optional cleaning and lining of the firsttrenches 103, using either a chemical vapor deposition (CVD) method(e.g., the HARP process), a high density plasma CVD method, or othersuitable method of formation as is known in the art.

The first trenches 103 may be filled by overfilling the first trenches103 and the substrate 101 with the dielectric material and then removingthe excess material outside of the first trenches 103 and the fins 105through a suitable process such as chemical mechanical polishing (CMP),an etch, a combination of these, or the like. In an embodiment, theremoval process removes any dielectric material that is located over thefins 105 as well, so that the removal of the dielectric material willexpose the surface of the fins 105 to further processing steps.

Once the first trenches 103 have been filled with the dielectricmaterial, the dielectric material may then be recessed away from thesurface of the fins 105. The recessing may be performed to expose atleast a portion of the sidewalls of the fins 105 adjacent to the topsurface of the fins 105. The dielectric material may be recessed using awet etch by dipping the top surface of the fins 105 into an etchant suchas HF, although other etchants, such as H₂, and other methods, such as areactive ion etch, a dry etch with etchants such as NH₃/NF₃, chemicaloxide removal, or dry chemical clean may be used. The dielectricmaterial may be recessed to a second distance D₂ from the surface of thefins 105 of between about 50 Å and about 500 Å, such as about 400 Å.Additionally, the recessing may also remove any leftover dielectricmaterial located over the fins 105 to ensure that the fins 105 areexposed for further processing.

As one of ordinary skill in the art will recognize, however, the stepsdescribed above may be only part of the overall process flow used tofill and recess the dielectric material. For example, lining steps,cleaning steps, annealing steps, gap filling steps, combinations ofthese, and the like may also be utilized to form and fill the firsttrenches 103 with the dielectric material. All of the potential processsteps are fully intended to be included within the scope of the presentembodiment.

After the first isolation regions 107 have been formed, a gatedielectric 109 (not visible in FIG. 1 but visible in the cross-sectionof FIG. 3B), a gate electrode 111 over the gate dielectric 109, andfirst spacers 113 may be formed over each of the fins 105. In anembodiment the gate dielectric 109 may be formed by thermal oxidation,chemical vapor deposition, sputtering, or any other methods known andused in the art for forming a gate dielectric. Depending on thetechnique of gate dielectric formation, the gate dielectric 109thickness on the top of the fins 105 may be different from the gatedielectric thickness on the sidewall of the fins 105.

The gate dielectric 109 may comprise a material such as silicon dioxideor silicon oxynitride with a thickness ranging from about 3 angstroms toabout 100 angstroms, such as about 10 angstroms. The gate dielectric 109may be formed from a high permittivity (high-k) material (e.g., with arelative permittivity greater than about 5) such as lanthanum oxide(La₂O₃), aluminum oxide (Al₂O₃), hafnium oxide (HfO₂), hafniumoxynitride (HfON), or zirconium oxide (ZrO₂), or combinations thereof,with an equivalent oxide thickness of about 0.5 angstroms to about 100angstroms, such as about 10 angstroms or less. Additionally, anycombination of silicon dioxide, silicon oxynitride, and/or high-kmaterials may also be used for the gate dielectric 109.

The gate electrode 111 may comprise a conductive material and may beselected from a group comprising of polycrystalline-silicon (poly-Si),poly-crystalline silicon-germanium (poly-SiGe), metallic nitrides,metallic silicides, metallic oxides, metals, combinations of these, andthe like. Examples of metallic nitrides include tungsten nitride,molybdenum nitride, titanium nitride, and tantalum nitride, or theircombinations. Examples of metallic silicide include tungsten silicide,titanium silicide, cobalt silicide, nickel silicide, platinum silicide,erbium silicide, or their combinations. Examples of metallic oxidesinclude ruthenium oxide, indium tin oxide, or their combinations.Examples of metal include tungsten, titanium, aluminum, copper,molybdenum, nickel, platinum, etc.

The gate electrode 111 may be deposited by chemical vapor deposition(CVD), sputter deposition, or other techniques known and used in the artfor depositing conductive materials. The thickness of the gate electrode111 may be in the range of about 200 angstroms to about 4,000 angstroms.The top surface of the gate electrode 111 may have a non-planar topsurface, and may be planarized prior to patterning of the gate electrode111 or gate etch. Ions may or may not be introduced into the gateelectrode 111 at this point. Ions may be introduced, for example, by ionimplantation techniques.

Once formed, the gate dielectric 109 and the gate electrode 111 may bepatterned to form a series of gate stacks 115 over the fins 105. Thegate stacks 115 define multiple channel regions located on each side ofthe fins 105 beneath the gate dielectric 109. The gate stacks 115 may beformed by depositing and patterning a gate mask (not shown) on the gateelectrode 111 using, for example, deposition and photolithographytechniques known in the art. The gate mask may incorporate commonly usedmasking materials, such as (but not limited to) photoresist material,silicon oxide, silicon oxynitride, and/or silicon nitride. The gateelectrode 111 and the gate dielectric 109 may be etched using a dryetching process to form the patterned gate stacks 115.

Once the gate stacks 115 have been patterned, the first spacers 113 maybe formed. The first spacers 113 may be formed on opposing sides of thegate stacks 115. The first spacers 113 are typically formed by blanketdepositing a spacer layer (not separately illustrated in FIG. 1) on thepreviously formed structure. The spacer layer may comprise SiN,oxynitride, SiC, SiON, oxide, and the like and may be formed by methodsutilized to form such a layer, such as chemical vapor deposition (CVD),plasma enhanced CVD, sputter, and other methods known in the art. Thespacer layer may comprise a different material with different etchcharacteristics or the same material as the dielectric material withinthe first isolation regions 107. The first spacers 113 may then bepatterned, such as by one or more etches to remove the spacer layer fromthe horizontal surfaces of the structure, to form the first spacers 113.

FIG. 2 illustrates a removal of the fins 105 from those areas notprotected by the gate stacks 115 and the first spacers 113. This removalmay be performed by a reactive ion etch (RIE) using the gate stacks 115and the first spacers 113 as hardmasks, or by any other suitable removalprocess. The removal may be continued until the fins 105 are eitherplanar with or below the surface of the first isolation regions 107.

FIGS. 3A-3C illustrate a regrowth of material to form source/drainregions 301 in contact with each of the fins 105, with FIGS. 3B and 3Cbeing cross-sectional views of FIG. 3A along lines B-B′ and C-C′,respectively. In an embodiment wherein the fins 105 comprise silicon,the source/drain regions 301 may be regrown through a selectiveepitaxial process with a doped material such as silicon phosphorous(SiP). However, any suitable material may be utilized.

In an embodiment the epitaxial growth process used to form thesource/drain regions 301 may utilize an epitaxial growth system 300 suchas illustrated in FIG. 3D. The epitaxial growth system 300 may beutilized to receive precursor materials from a first precursor deliverysystem 305, a second precursor delivery system 306, a third precursordelivery system 308, and a fourth precursor delivery system 310, andform layers of materials (e.g., the source/drain regions 301) on thesubstrate 101 and the fins 105. In an embodiment the first precursordelivery system 305, the second precursor delivery system 306, the thirdprecursor delivery system 308, and the fourth precursor delivery system310 work in conjunction with one another to supply the various differentprecursor materials to an epitaxial growth chamber 303 wherein thesubstrate 101 (and consequently the fins 105) are placed. However, thefirst precursor delivery system 305, the second precursor deliverysystem 306, the third precursor delivery system 308, and the fourthprecursor delivery system 310 may have physical components that aresimilar with each other.

For example, the first precursor delivery system 305, the secondprecursor delivery system 306, the third precursor delivery system 308,and the fourth precursor delivery system 310 may each include a gassystem 307 and a flow controller 309 (labeled in FIG. 3D with regards tothe first precursor delivery system 305 but not labeled for clarity withrespect to the second precursor delivery system 306, the third precursordelivery system 308, and the fourth precursor delivery system 310). Inan embodiment in which the first precursor is stored in a gaseous state,the gas system 307 may supply the first precursor to the epitaxialgrowth chamber 303. The gas system 307 may be a vessel, such as a gasstorage tank, that is located either locally to the epitaxial growthchamber 303 or else may be located remotely from the epitaxial growthchamber 303. In another embodiment, the gas system 307 may be a facilitythat independently prepares and delivers the first precursor to the flowcontroller 309. Any suitable source for the first precursor may beutilized as the gas system 307, and all such sources are fully intendedto be included within the scope of the embodiments.

The gas system 307 may supply the desired precursor to the flowcontroller 309. The flow controller 309 may be utilized to control theflow of the precursor to the precursor gas controller 313 and,eventually, to the epitaxial growth chamber 303, thereby also helping tocontrol the pressure within the epitaxial growth chamber 303. The flowcontroller 309 may be, e.g., a proportional valve, a modulating valve, aneedle valve, a pressure regulator, a mass flow controller, combinationsof these, or the like. However, any suitable method for controlling andregulating the flow of the first precursor may be utilized, and all suchcomponents and methods are fully intended to be included within thescope of the embodiments.

Additionally, in an embodiment in which the first precursor is stored ina solid or liquid state, the gas system 307 may also store or receive acarrier gas and the carrier gas may be introduced into a precursorcanister (not separately illustrated), which stores the first precursorin the solid or liquid state. The carrier gas is then used to push andcarry the first precursor as it either evaporates or sublimates into agaseous section of the precursor canister before being sent to theprecursor gas controller 313. Any suitable method and combination ofunits may be utilized to provide the first precursor, and all suchcombinations of units are fully intended to be included within the scopeof the embodiments.

However, as one of ordinary skill in the art will recognize, while thefirst precursor delivery system 305, the second precursor deliverysystem 306, the third precursor delivery system 308, and the fourthprecursor delivery system 310 have been described herein as havingidentical components, this is merely an illustrative example and is notintended to limit the embodiments in any fashion. Any type of suitableprecursor delivery system, with any type and number of individualcomponents identical to or different from any of the other precursordelivery systems within the epitaxial growth system 300, may beutilized. All such precursor systems are fully intended to be includedwithin the scope of the embodiments.

The first precursor delivery system 305, the second precursor deliverysystem 306, the third precursor delivery system 308, and the fourthprecursor delivery system 310 may supply their individual precursormaterials into a precursor gas controller 313. The precursor gascontroller 313 connects and isolates the first precursor delivery system305, the second precursor delivery system 306, the third precursordelivery system 308, and the fourth precursor delivery system 310 fromthe epitaxial growth chamber 303 in order to deliver the desiredprecursor materials to the epitaxial growth chamber 303 (discussedfurther below). The precursor gas controller 313 may include suchdevices as valves, flow meters, sensors, and the like to control thedelivery rates of each of the precursors, and may be controlled byinstructions received from the control unit 315 (described further belowwith respect to FIG. 3E).

The precursor gas controller 313, upon receiving instructions from thecontrol unit 315, may open and close valves so as to connect one or moreof the first precursor delivery system 305, the second precursordelivery system 306, the third precursor delivery system 308, and thefourth precursor delivery system 310 to the epitaxial growth chamber 303and direct a desired precursor material through a manifold 316, into theepitaxial growth chamber 303, and to a showerhead 317. The showerhead317 may be utilized to disperse one or more of the chosen precursormaterials into the epitaxial growth chamber 303 and may be designed toevenly disperse the precursor material in order to minimize undesiredprocess conditions that may arise from uneven dispersal. In anembodiment the showerhead 317 may have a circular design with openingsdispersed evenly around the showerhead 317 to allow for the dispersal ofthe desired precursor materials into the epitaxial growth chamber 303.

However, as one of ordinary skill in the art will recognize, theintroduction of precursor materials to the epitaxial growth chamber 303through a single showerhead 317 or through a single point ofintroduction as described above is intended to be illustrative only andis not intended to be limiting to the embodiments. Any number ofseparate and independent showerheads 317 or other openings to introducethe various precursor materials into the epitaxial growth chamber 303may be utilized. All such combinations of showerheads and other pointsof introduction are fully intended to be included within the scope ofthe embodiments.

The epitaxial growth chamber 303 may receive the desired precursormaterials and expose the precursor materials to the substrate 101 andthe fins 105, and the epitaxial growth chamber 303 may be any desiredshape that may be suitable for dispersing the precursor materials andcontacting the precursor materials with the substrate 101 and the fins105. In the embodiment illustrated in FIG. 3D, the epitaxial growthchamber 303 has a cylindrical sidewall and a bottom. However, theepitaxial growth chamber 303 is not limited to a cylindrical shape, andany other suitable shape, such as a hollow square tube, an octagonalshape, or the like, may be utilized. Furthermore, the epitaxial growthchamber 303 may be surrounded by a housing 319 made of material that isinert to the various process materials. As such, while the housing 319may be any suitable material that can withstand the chemistries andpressures involved in the deposition process, in an embodiment thehousing 319 may be steel, stainless steel, nickel, aluminum, alloys ofthese, combinations of these, and like.

Within the epitaxial growth chamber 303 the substrate 101 may be placedon a mounting platform 321 in order to position and control thesubstrate 101 and the fins 105 during the epitaxial growth processes.The mounting platform 321 may include heating mechanisms in order toheat the substrate 101 during the epitaxial growth processes.Furthermore, while a single mounting platform 321 is illustrated in FIG.3D, any number of mounting platforms 321 may additionally be includedwithin the epitaxial growth chamber 303.

Additionally, the epitaxial growth chamber 303 and the mounting platform321 may be part of a cluster tool system (not shown). The cluster toolsystem may be used in conjunction with an automated handling system inorder to position and place the substrate 101 into the epitaxial growthchamber 303 prior to the epitaxial growth processes, position, hold thesubstrate 101 during the epitaxial growth processes, and remove thesubstrate 101 from the epitaxial growth chamber 303 after the epitaxialgrowth processes.

The epitaxial growth chamber 303 may also have an exhaust outlet 325 forexhaust gases to exit the epitaxial growth chamber 303. A vacuum pump323 may be connected to the exhaust outlet 325 of the epitaxial growthchamber 303 in order to help evacuate the exhaust gases. The vacuum pump323, under control of the control unit 315, may also be utilized toreduce and control the pressure within the epitaxial growth chamber 303to a desired pressure and may also be utilized to evacuate precursormaterials from the epitaxial growth chamber 303 in preparation for theintroduction of the next precursor material.

FIG. 3E illustrates an embodiment of the control unit 315 that may beutilized to control the precursor gas controller 313 and the vacuum pump323 (as illustrated in FIG. 3D). The control unit 315 may be any form ofcomputer processor that can be used in an industrial setting forcontrolling process machines. In an embodiment the control unit 315 maycomprise a processing unit 351, such as a desktop computer, aworkstation, a laptop computer, or a dedicated unit customized for aparticular application. The control unit 315 may be equipped with adisplay 353 and one or more input/output components 355, such asinstruction outputs, sensor inputs, a mouse, a keyboard, printer,combinations of these, or the like. The processing unit 351 may includea central processing unit (CPU) 356, memory 358, a mass storage device360, a video adapter 364, and an I/O interface 366 connected to a bus362.

The bus 362 may be one or more of any type of several bus architecturesincluding a memory bus or memory controller, a peripheral bus, or videobus. The CPU 356 may comprise any type of electronic data processor, andthe memory 358 may comprise any type of system memory, such as staticrandom access memory (SRAM), dynamic random access memory (DRAM), orread-only memory (ROM). The mass storage device 360 may comprise anytype of storage device configured to store data, programs, and otherinformation and to make the data, programs, and other informationaccessible via the bus 362. The mass storage device 360 may comprise,for example, one or more of a hard disk drive, a magnetic disk drive, oran optical disk drive.

The video adapter 364 and the I/O interface 366 provide interfaces tocouple external input and output devices to the processing unit 351. Asillustrated in FIG. 3E, examples of input and output devices include thedisplay 353 coupled to the video adapter 364 and the I/O component 355,such as a mouse, keyboard, printer, and the like, coupled to the I/Ointerface 366. Other devices may be coupled to the processing unit 356,and additional or fewer interface cards may be utilized. For example, aserial interface card (not shown) may be used to provide a serialinterface for a printer. The processing unit 351 also may include anetwork interface 368 that may be a wired link to a local area network(LAN) or a wide area network (WAN) 370 and/or a wireless link.

It should be noted that the control unit 315 may include othercomponents. For example, the control unit 315 may include powersupplies, cables, a motherboard, removable storage media, cases, and thelike. These other components, although not shown in FIG. 3E, areconsidered part of the control unit 315.

In preparation for the formation of the source/drain regions 301, afirst precursor material is placed into or formed by the first precursordelivery system 305. For example, in an embodiment in which a dopedsemiconductor material such as silicon phosphorous is desired to begrown, the first precursor material may be a silicon-containingprecursor material such as dichlorosilane (DCS), although other suitableprecursors, such as silane (SiH₄) or disilane (Si₂H₆), may also beutilized. All suitable precursor materials are fully intended to beincluded within the scope of the embodiments.

Additionally, a second precursor material may be placed into or formedby the second precursor delivery system 306. In the embodiment thesecond precursor may be used to provide a doping material thatcomplements the semiconductor material present in the first precursormaterial. For example, in an embodiment in which a layer of silicondoped with phosphorous (SiP) is desired to be grown as the source/drainregions 301 and the first precursor material is dichlorosilane, thesecond precursor material may be a material that comprises the desireddopant such as phosphorous (P). In a particular embodiment the secondprecursor material is PH₃. However, any suitable dopant containingmaterial, such as arsenic (As) or antimony (Sb), may be utilized andplaced within the second precursor delivery system 306.

In addition to the first precursor material and the second precursormaterial that are collectively utilized to grow the desired material(e.g., SiP), an etching precursor may also be utilized during the growthprocess, and may be placed in the third precursor delivery system 308.In an embodiment in which the material to be grown will at leastpartially deposit on materials other than the exposed fins 105 (such asby growing on the exposed surfaces of the first spacers 113), theaddition of an etching precursor will work to remove epitaxially grownmaterial from these undesired locations, and helps to cause theselective growth be more selective. In an embodiment the etchingprecursor is a precursor that will remove undesired growth of the grownmaterial while still allowing for growth of the desired material overthe fins 105, and may be an etchant such as hydrochloric acid (HCl).However, any suitable etching precursor may be utilized.

Finally, in order to help control the three-dimensional shape of thesource/drain regions 301 during the epitaxial growth process by helpingthe etching efficiency of the etching precursor during a cleaningprocess (discussed further below), a shaping precursor may be placed inthe fourth precursor delivery system 310. In an embodiment the shapingprecursor is a material that, when incorporated into the source/drainregions 301 during the cleaning process, will help to amorphize andmodify the crystalline structure of the source/drain regions 301 thathas already been grown prior to introduction of the shaping precursor.In a particular embodiment in which the grown material is siliconphosphorous, the shaping precursor is a material that comprises amaterial with a different crystalline lattice constant, such asgermanium. In a particular embodiment the shaping precursor is GeH₄.However, any suitable shaping precursor may be utilized.

Once the first precursor material, the second precursor material, theetching precursor and the shaping precursor are ready in the firstprecursor delivery system 305, the second precursor delivery system 306,the third precursor delivery system 308, and the fourth precursordelivery system 310, respectively, the formation of the source/drainregions 301 may be initiated by the control unit 315 sending aninstruction to the precursor gas controller 313 to start a first step601 and connect the first precursor delivery system 305, the secondprecursor delivery system 306, and the third precursor delivery system308 to the epitaxial growth chamber 303. Once connected, the firstprecursor delivery system 305, the second precursor delivery system 306and the third precursor delivery system 308 can deliver the firstprecursor material (e.g., dichlorosilane), the second precursor material(e.g., PH₃), and the etching precursor (e.g., HCl) to the showerhead 317through the precursor gas controller 313 and the manifold 316. Theshowerhead 317 can then disperse the first precursor material, thesecond precursor material, and the etching precursor into the epitaxialgrowth chamber 303, wherein the first precursor material and the secondprecursor material can react to the exposed surface of the fins 105 andbegin to grow a bulk section 331 of the source/drain regions 301 on theexposed sections of the fins 105.

In an embodiment in which the source/drain regions 301 are, e.g., SiP,the first precursor material (e.g., dichlorosilane) may be flowed intothe epitaxial growth chamber 303 at a flow rate of between about 10 sccmand about 10000 sccm, such as about 500 sccm while the second precursormaterial (e.g., PH₃) is flowed into the epitaxial growth chamber 303 ata flow rate of between about 10 sccm and about 1000 sccm, such as about100 sccm. Additionally, the epitaxial growth chamber 303 during thefirst step 601 may be held at a pressure of between about 5 Torr andabout 1000 Torr, such as about 100 Torr, and a temperature of betweenabout 400° C. and about 1000° C., such as about 600° C. However, as oneof ordinary skill in the art will recognize, these process conditionsare only intended to be illustrative, as any suitable process conditionsmay be utilized while remaining within the scope of the embodiments.

Additionally, while the first precursor material and the secondprecursor material are being introduced into the epitaxial growthchamber 303, the first precursor material and the second precursormaterial will react not solely on the fins 105 (where the growth isdesired), but may also occur on other structures, such as the firstspacers 113 (where the growth is not desired). To remove this undesiredgrowth, the etching precursor is also added during the first step 601 ofthe growth process along with the first precursor material and thesecond precursor material. In an embodiment in which the source/drainregions 301 are SiP and the etching precursor is hydrochloric acid, theetching precursor may be flowed into the epitaxial growth chamber 303 ata flow rate of between about 10 sccm and about 30000 sccm, such as about100 sccm. Such a flow rate will work to remove grown material fromsurfaces where it is undesired. However, any suitable flow rate may beutilized.

However, as the etching precursor is cleaning the undesired surfacesduring the initial growth stage of the source/drain regions 301 (e.g.,the first step 601) along with the first precursor material and thesecond precursor material, the etching precursor will also react withthe material of the bulk section 331 of the source/drain region 301 asit is being grown. However, as the material of the bulk section 331(e.g., SiP) is grown, the etching precursor will preferentially etchthose surfaces of the bulk section 331 of the source/drain region 301that are oriented in a (110) direction, such as the sidewalls of thegrown material. As such, the etching precursor will have a first lateraletch rate (in the direction of the arrow labeled 330 in FIG. 3A) duringthe first step 601 of between about 0.1 nm/min and about 100 nm/min,such as about 10 nm/min. However, any suitable lateral etch rate may beutilized.

In an embodiment the growth of the source/drain regions 301 in the firststep 601 is continued to grow a bulk section 331 of the source/drainregions 301. For example, the first step 601 may be continued for a timeperiod of between about 10 seconds and about 1000 seconds, such as about500 seconds. However, any suitable time may be utilized.

By forming the bulk section 331 of the source/drain regions 301 asdescribed above, the bulk section 331 of the source/drain regions 301may be formed with a relatively consistent concentration of the dopant(e.g., phosphorous). In an embodiment the bulk section 331 of thesource/drain regions 301 may be formed to have a first dopantconcentration of between about 1E+20 atom/cm³ and about 1E+23 atom/cm³,such as about 1E+21 atom/cm³. However, any suitable concentration may beused.

Additionally, while the source/drain regions 301 are being grown upwardson the fins 105, growth will also occur in a horizontal direction aswell. While part of the growth for the source/drain regions 301 willeventually meet and merge in a region between the fins 105, as thesource/drain region 301 extends horizontally away from the fins (e.g.,to the left and right of the figures), separate ones of the source/drainregions 301 for different devices (not separately illustrated) may growinto each other, forming an undesired connection between what areintended to be separate source/drain regions 301. Such growth could leadto undesired connections and defects within the finished product.

As such, to help increase the efficiency of the etching precursor andhelp better shape the source/drain regions 301 such that they do notundesirably grow together, a second step 603, such as a cleaning step,is performed that introduces the shaping precursor. In an embodiment thesecond step 603 may be initiated by the control unit 315 sending aninstruction to the precursor gas controller 313 to disconnect the firstprecursor delivery system 305 and the second precursor delivery system306 from the epitaxial growth chamber 303, thereby stopping the flow ofthe first precursor and the second precursor from continuing to enterthe epitaxial growth chamber 303.

Additionally, the control unit 315 will also continue the flow of theetching precursor after the disconnection of the first precursordelivery system 305 and the second precursor delivery system 306. In anembodiment the etching precursor in the second step 603 may be flowedinto the epitaxial growth chamber 303 at a flow rate of between about 10sccm and about 30000 sccm, such as about 100 sccm. Additionally, theepitaxial growth chamber 303 during the second step 603 may be held at apressure of between about 5 Torr and about 1000 Torr, such as about 100Torr, and a temperature of between about 400° C. and about 1000° C.,such as about 600° C. However, as one of ordinary skill in the art willrecognize, these process conditions are only intended to beillustrative, as any suitable process conditions may be utilized whileremaining within the scope of the embodiments.

Additionally, in order to help the cleaning process, the control unit315 will also send an instruction to the precursor gas controller 313 toconnect the fourth precursor delivery system 310. By connecting thefourth precursor delivery system 310, the control unit 315 willintroduce the shaping precursor (e.g., GeH₄) into the epitaxial growthchamber 303 at the same time as the etching precursor (e.g., HCl). In anembodiment in which the material of the source/drain regions 301 is SiP,the etching precursor is HCl, and the shaping precursor is GeH₄, theshaping precursor may be flowed into the epitaxial growth chamber 303 ata flow rate of between about 10 sccm and about 10000 sccm, such as about100 sccm. Additionally, the shaping precursor and etching precursor maybe flowed together for a time of between about 10 seconds and about 500seconds, such as about 100 seconds. However, any suitable flow rate andtime may be utilized.

With the introduction of the shaping precursor, the shaping precursor(e.g., GeH₄) will react with the material of the bulk section 331 of thesource/drain regions 301 that has already been deposited (e.g., SiP)through processes that include HCl/GeH₄ adsorption, segregation, SiCL₂desorption etching, H₂ desorption, and the removal of GeCl₂ and SiCl₂.These reaction processes will work to clean the bulk section 331 of thesource/drain regions 301 and will also incorporate a portion of theshaping precursor (e.g., germanium) into the material of thesource/drain regions 301 to form a shaping section 333 or cleaningsection of the source/drain region 301. In an embodiment in which thesource/drain regions 301 are SiP and the shaping precursor is GeH₄, thegermanium from the GeH₄ will react with the SiP that has already beendeposited and the germanium will become incorporated into a portion ofthe source/drain regions 301, exchanging places with silicon atoms anddiffusing into silicon alloys that can reduce the silicon bonding energyand modify the crystalline structure. Such a reduction in the bondingenergy can help achieve a better silicon etching efficiency and achievean overall better shape for the epitaxially grown source/drain regions301.

In an embodiment, after the second step 603, the bulk section 331 of thesource/drain region 301 may have a first thickness T₁ over the fins 105of between about 10 nm and about 100 nm, such as about 50 nm and theshaping section 333 of the source/drain regions 301 may have a secondthickness T₂ of between about 1 nm and about 50 nm, such as about 10 nm.Additionally, the shaping section 333 may also have an atomicconcentration of germanium of between about 1% and about 10%. However,any suitable concentration of germanium may also be used.

By incorporating the material of the shaping precursor, the crystallinestructure of the exposed surfaces of the source/drain region 301 will bemodified and the silicon bonding energy will be reduced. In a particularembodiment, by forming the shaping section 333 of the source/drainregions 301 out of the bulk section 331 of the source/drain regions 301,the bonding energy of the silicon within the exposed surfaces of theshaping section 333 of the source/drain regions 301 will have adecreased bonding energy. Additionally, given that hydrochloric acidwill preferentially react with surfaces oriented along the (110)direction, such a lowering of the bonding energy within the shapingsection 333 of the source/drain regions 301 will enhance the etchingprecursor (e.g., HCl) preferential reaction and removal of the surfacesof the sidewalls while not removing as much of the material at the topof the source/drain regions 301 (e.g., in the (100) direction). As such,the etching precursor may have a second lateral etch rate in the secondstep 603 that is higher than the first lateral etch rate of the firststep 601, such as by being between about 0.2 nm/min and about 100nm/min, such as about 15 nm/min.

Data regarding the increase in etch rate both in general as well as withrespect to a ratio between lateral and vertical etching may be seen inFIGS. 4A-4B. In particular, FIG. 4A illustrates that, without theincorporation of the germanium, blanket deposited silicon will have abonding energy of about 76 kcal/mol and have a first etch rate along a[110] direction. However, with the introduction of germanium into thesilicon (and with the effect being larger as more silicon isintroduced), the etch rate of silicon along the [110] orientationincreases along with the amount of germanium. Additionally, looking atFIG. 4B, this figure illustrates the increase in the ratio between thelateral etch rate and the vertical etch rate of silicon when increasinglevels of germanium are added. As can be seen, as more germanium isadded, the ratio of the lateral etch rate to the vertical etch rate alsoincreases.

Such a preferential reaction with and removal of material from thesidewalls of the shaping section 333 of the source/drain regions 301instead of the top of the shaping section 333 of the source/drainregions 301 will work to make the overall source/drain regions 301thinner than would otherwise be possible for a particular height, andwill also help to separate the different ones of the source/drainregions 301 and keep them from undesirably merging with other fins 105(not separately illustrated in FIG. 3A).

Once the second step 603 has been completed, a third step 605 may beperformed in order to continue the epitaxial growth of the source/drainregions 301 after the second step 603. In an embodiment the third step605 may be initiated by the control unit 315 sending an instruction tothe precursor gas controller 313 to disconnect the fourth precursordelivery system 310 and stop the flow of the shaping precursor to theepitaxial growth chamber 303. With the flow of the shaping precursor tothe epitaxial growth chamber 303 stopped, the control unit 315 will sendan instruction to the precursor gas controller 313 to re-connect thefirst precursor delivery system 305 and the second precursor deliverysystem 306 (along with the third precursor delivery system 308). In anembodiment the process conditions and flow rates of the first precursor,the second precursor, and the etching precursor for the third step 605may be as described above with respect to the first step 601, althoughin other embodiments they may be different.

The third step 605 may be continued to form a finishing section 335 ofthe source/drain regions 301 over the shaping section 333 of thesource/drain regions 301. In an embodiment the finishing section 335 ofthe source/drain regions 301 may be formed to have a third thickness T₃of between about 1 nm and about 50 nm, such as about 10 nm, and may beformed by continuing the process for a time of between about 10 secondand about 500 second, such as about 100 second. However, any suitablethickness and time of formation may be used.

However, in addition to simply forming another layer of material, thepresence of the shaping dopant (e.g., germanium) within the shapingsection 333 of the source/drain region 301 will not only help to makethe lateral etching more efficient (thereby leading to a taller andthinner source/drain region 301), but will also work to more effectivelyincorporate the dopants (e.g., P) from the second precursor into thesource/drain regions 301 as the source/drain regions 301 are beinggrown. As such, a concentration of the dopant within the finishingsection 335 will be higher than a concentration of the dopant within thebulk section 331 of the source/drain region 301. For example, in anembodiment in which phosphorous is being incorporated into thesource/drain regions 301, the phosphorous may have a secondconcentration in the finishing section 335 of between about 1E+20atom/cm³ and about 1E+24 atom/cm³, such as about 1.5E+21 atom/cm³.However, any suitable concentration may be utilized.

However, as one of ordinary skill in the art will recognize, the abovedescribed process is merely exemplary and is not intended to limit theembodiments. Rather, any suitable number of steps, such as purging theepitaxial growth chamber 303 between each of the first step 601, thesecond step 603, and the third step 605, and any other suitable steps,such as ramping steps and stabilization steps, may also be used, and allsuch combination of steps are fully intended to be included within thescope of the embodiments.

For example, the epitaxial growth system 300 may also include a purgegas delivery system 314 to deliver a purge gas to the epitaxial growthchamber 303. In an embodiment the purge gas delivery system 314 may be agaseous tank or other facility that provides a purge gas such asnitrogen, argon, xenon, or other non-reactive gas to the epitaxialgrowth chamber 303. Additionally, during a purge the control unit 315may also initiate the vacuum pump 323 in order to apply a pressuredifferential to the epitaxial growth chamber 303 to aid in the removalof the precursor materials between the various steps, such as betweenthe first step 601, the second step 603, and the third step 605. Thepurge gas, along with the vacuum pump 323, may purge the precursormaterials from the epitaxial growth chamber 303.

By using the first step 601, the second step 603, and the third step 605as described above, a greater degree of control over the shape of thesource/drain regions 301 may be achieved. For example, the source/drainregions 301 may have a planar top surface (with a wavy depth D_(w) ofzero; see FIG. 3F below for an embodiment with a wavy depth D_(w)greater than zero) and may also have a raise height H_(R) at the end ofthe deposition process of between about 10 nm and about 100 nm.Additionally, the source/drain region 301 may also have a criticaldimension width W_(CD) of between about 10 nm and about 200 nm. As such,the source/drain region 301 may have a height to width ratio of betweenabout 0.5 and about 10, such as about 1 or 0.5. However, any suitabledimensions may be utilized.

After the source/drain regions 301 have been formed, an optionalsilicide process can be used to form silicide contacts (not shown) alongthe source/drain regions 301. The silicide contacts may comprise nickel,cobalt, platinum, or erbium in order to reduce the Schottky barrierheight of the contact. However, other commonly used metals, such astitanium, palladium, and the like, may also be used. As is known in theart, the silicidation may be performed by blanket deposition of anappropriate metal layer, followed by an annealing step which causes themetal to react with the underlying exposed silicon. Un-reacted metal isthen removed, such as through a selective etch process, and a secondanneal may be performed for a silicide phase adjustment. The thicknessof the silicide contacts may be between about 5 nm and about 50 nm.

Once formed, additional processing steps may be performed in order tocontinue the manufacturing process of the semiconductor device. Forexample, an interlayer dielectric may be deposited over the fins 105,and contacts (not separately illustrated) may be formed to electricallyconnect the gate electrode 111 and the source/drain regions 301 tooverlying metallization layers (not separately illustrated). In anotherembodiment the gate electrode 111 may be removed and replaced withanother material. Any other suitable front end of line processing orback end of line processing may be used to help complete thesemiconductor device for a finished product.

FIG. 3F illustrates another embodiment in which the top surface of thesource/drain regions 301 is not planar (as described above with respectto FIG. 3C). Rather, in this embodiment there are a number of waves 336that extend into the top surface of the source/drain region 301. In thisembodiment each of the individual waves 336 may have a wavy depth Dwthat is greater than zero and less than or equal to about 30 nm.However, any suitable depth may be utilized. The wavy depth Dw may bemodified by changing the process conditions for the introduction of theshaping precursor (e.g., germanium). For example, in an embodiment inwhich the wavy depth D_(w) is less than or equal to about 30 nm, theprocess conditions for the introduction of the shaping precursor mayinclude a shaping precursor flow rate of between about 10 sccm and about30000 sccm.

FIGS. 5A-5B are charts that illustrate the germanium and phosphorousconcentrations in atomic percentages of the same sample after using aprocess such as described above with respect to FIGS. 1-3F. As can beseen, in each embodiment the germanium concentration increases withinthe shaping section 333, and decreases on either side of the shapingsection 333. Additionally, the phosphorous concentration is relativelystable within the bulk section 331 of the source/drain region 301, dipsdown slightly at the transition between the bulk section 331 of thesource/drain region 301 and the shaping section 333 of the source/drainregion 301, and then increases again within the shaping section 333.

FIG. 6 illustrates a summary of the process steps described above thatare used to form the bulk section 331, the shaping section 333, and thefinishing section 335 of the source/drain regions 301. In the first step601, the bulk section 331 of the source/drain region 301 is formed usingthe first precursor, the second precursor, and the etching precursor. Inthe second step 603, the shaping section 333 of the source/drain regions301 is formed using the shaping precursor and the etching precursor.Finally, in the third step 605, the finishing section 335 of thesource/drain regions 301 is formed using the first precursor, the secondprecursor, and the etching precursor.

By using the second step 603 to introduce the shaping precursor (e.g.,germanium), the etching efficiency of the etching precursor (e.g., HCl)may be improved during the epitaxial growth process. As such, a higheretching selectivity loss window may be achieved, and the shape of theepitaxial growth may be better controlled through an improvement in theselectivity loss. Accordingly, problems with smaller pitch sizes leadingto more marginal merge windows may be overcome.

FIGS. 7A-7C illustrate another embodiment in which the first isolationregions 107 are used to isolate the fins 105 from each other, and secondisolation regions 701 are used to isolate the fins 105 from othersections of the substrate 101 such as separate groupings of fins 105(not separately illustrated), with FIGS. 7B and 7C being cross-sectionalviews of FIG. 7A along lines B-B′ and C-C′, respectively. In thisembodiment the second isolation regions 701 may be formed by initiallyforming second trenches 703. The second trenches 703 may be formed priorto, after, or even partially along with the first trenches 103, such asby using a photolithographic masking and etching process similar to theprocess described above with respect to the formation of the firsttrenches 103. For example, in one embodiment openings for the secondtrenches 703 may be initially made within the substrate 101 with a firstmasking and etching process and then these openings may be extended atthe same time that the first trenches 103 are formed with a secondmasking and etching process. However, the second trenches 703 may beformed to extend a third distance D₃ from the top of the substrate 101and the fins 105 that is deeper than the first trenches 103. In aparticular embodiment the first trenches 103 may be formed to have adepth of between about 100 Å and about 1,500 Å, such as about 1,000 Å,and the second trenches 703 may be formed such that the third distanceD₃ is between about 200 Å and about 7,000 Å, such as about 3,190 Å.However, any suitable depths may be utilized.

Once the second trenches 703 have been formed along with the firsttrenches 103, the first trenches 103 and the second trenches 703 may befilled with the dielectric material to form the first isolation regions107 and the second isolation region 701. In an embodiment the firsttrenches 103 and the second trenches 703 may be filled as describedabove with respect to FIG. 1. For example, the dielectric material maybe deposited such that the dielectric material fills the first trenches103 and the second trenches 703, and then the dielectric material may berecessed to expose the top surfaces of the fins 105 and form the firstisolation regions 107 and the second isolation regions 701. Once thefirst isolation regions 107 and the second isolation regions 701 havebeen formed, processing may continue as described above to form the gatestacks 115 and the source/drain regions 301. For example, thesource/drain regions 301 may be formed with the bulk section 331, theshaping section 333, and the finishing section 335.

By utilizing the second isolation regions 701 along with the firstisolation regions 107, a better tuning of the isolation may be obtained.For example, the first isolation regions 107 may be tuned to thespecific desires of intra-fin isolation (between fins 105 covered by asame gate stack 115), while the second isolation regions 701 may betuned to the specific desires of inter-fin isolation (between fins 105covered by separated gate stack, not separately illustrated). Suchability to tune the isolation regions allows for greater processvariability.

FIG. 8 illustrates another embodiment in which the source/drain region301 is formed as part of a planar transistor 800. In this embodiment,shallow trench isolations 803 are initially formed within the substrate101 using a masking and etching process to form trenches within thesubstrate 101, filling the trenches with a dielectric material, and thenplanarizing the dielectric material with the substrate 101. Once theshallow trench isolations 803 have been formed, a planar transistor gatedielectric 805, a planar transistor gate electrode 807, and planartransistor spacers 809 are formed. For example, a layer of material forthe planar transistor gate dielectric 805 may be deposited or grown onthe substrate 101, followed by a layer of material for the planartransistor gate electrode 807. In an embodiment the materials anddeposition processes for the planar transistor gate dielectric 805 andthe planar transistor gate electrode 807 are as described above withrespect to the gate dielectric 109 and the gate electrode 111, althoughthey may be different.

Once the materials for the planar transistor gate dielectric 805 and theplanar transistor gate electrode 807 have been formed, the materials maybe patterned to form the planar transistor gate dielectric 805 and theplanar transistor gate electrode 807. The patterning may be performedusing a photolithographic masking and etching process. Once the planartransistor gate dielectric 805 and the planar transistor gate electrode807 have been patterned, the planar transistor spacers 809 may beformed. In an embodiment the planar transistor spacers 809 are formed asdescribed above with respect to the first spacers 113, although they maybe formed differently.

Once the planar transistor spacers 809 have been formed, openings forthe source/drain regions 301 may be formed within the substrate 101. Inan embodiment the openings for the source/drain regions 301 maybe formedwithin the substrate 101 using, e.g., a photolithographic masking andetching process. When the openings for the source/drain region 301 havebeen formed, the source/drain regions 301 may be grown within theopenings for the source/drain region 301. In an embodiment thesource/drain regions 301 may be regrown as described above with respectto FIGS. 3A-3E. For example, the substrate 101 may be placed within theepitaxial growth chamber 303, and the source/drain regions 301 may begrown with the bulk section 331, the shaping section 333, and thefinishing section 335.

By utilizing the growth process described with respect to FIGS. 3A-3Ewithin a planar transistor 800, the same benefits may be achieved forshaping and control for a FinFET process may also be applied to a planartransistor. For example, by modifying the lateral etch rate of theetching precursor, a higher and more narrow source/drain region 301 maybe obtained.

In an embodiment, a semiconductor device includes: a channel regionwithin a semiconductor material; and a source/drain region adjacent tothe channel region, where the source/drain region has a height to widthratio of between about 0.5 and about 10 and includes: a bulk region witha first concentration of a first dopant; an interface region with asecond concentration of the first dopant less than the firstconcentration; and a cleaning region with a third concentration of thefirst dopant greater than the second concentration.

In some embodiments of the semiconductor device, the first dopant isphosphorous. In some embodiments of the semiconductor device, thecleaning region includes a shaping dopant that is not present in thebulk region. In some embodiments of the semiconductor device, theshaping dopant is germanium. In some embodiments of the semiconductordevice, the germanium has a concentration within the cleaning region ofbetween about 1% and about 10%. In some embodiments of the semiconductordevice, the first concentration is between about 1E+20 atom/cm3 andabout 1E+23 atom/cm3 and the second concentration is between about 1E+20atom/cm3 and about 1E+24 atom/cm3. In some embodiments of thesemiconductor device, the cleaning region has a thickness of betweenabout 1 nm and about 50 nm. In some embodiments of the semiconductordevice, the source/drain region has a planar top surface.

In an embodiment, a semiconductor device includes: a fin extending froma substrate, the fin including a first semiconductive material; asource/drain region in the fin, the source/drain region including thefirst semiconductive material and a first dopant, the source/drainregion further including: a bulk section, a concentration of the firstdopant increasing through the bulk section from a bottom of the bulksection to a midpoint of the bulk section, the concentration of thefirst dopant decreasing through the bulk section from the midpoint ofthe bulk section to a top of the bulk section; a shaping section on thebulk section, the concentration of the first dopant increasing throughthe shaping section from a bottom of the shaping section to a midpointof the shaping section, the concentration of the first dopant decreasingthrough the shaping section from the midpoint of the shaping section toa top of the shaping section, the shaping section having a thickness ofbetween about 1 nm and about 50 nm; and a finishing section on theshaping section, the concentration of the first dopant decreasingthrough the finishing section from a bottom of the finishing section toa top of the finishing section.

In some embodiments of the semiconductor device, the first dopant isphosphorous. In some embodiments of the semiconductor device, thesource/drain region further includes a second dopant, a concentration ofthe second dopant in the shaping section being greater than aconcentration of the second dopant in the bulk section and aconcentration of the second dopant in the finishing section. In someembodiments of the semiconductor device, the second dopant is germanium.In some embodiments of the semiconductor device, the germanium has aconcentration within the shaping section of between about 1% and about10%. In some embodiments of the semiconductor device, the source/drainregion has a height to width ratio of between about 0.05 and about 10.In some embodiments of the semiconductor device, the source/drain regionhas a planar top surface.

In an embodiment, a semiconductor device includes: a plurality of finsextending from a substrate, each of the fins having a channel region; asource/drain region contacting each of the fins, the source/drain regionhaving a planar top surface, the source/drain region having a height towidth ratio of between about 0.05 and about 10, the source/drain regionincluding: a bulk section adjacent the channel region of each of thefins, the bulk section including a first dopant; a shaping section onthe bulk section, the shaping section including the first dopant, theshaping section having a thickness of between about 1 nm and about 50nm; and a finishing section on the shaping section, the finishingsection including the first dopant, where a concentration of the firstdopant at an interface of the bulk section and the shaping section isless than a concentration of the first dopant in the bulk section andless than a concentration of the first dopant in the shaping section.

In some embodiments of the semiconductor device, the first dopant isphosphorous. In some embodiments of the semiconductor device, the bulksection, the shaping section, and the finishing section further includea second dopant, a concentration of the second dopant in the shapingsection being greater than a concentration of the second dopant in thebulk section and a concentration of the second dopant in the finishingsection. In some embodiments of the semiconductor device, the seconddopant is germanium. In some embodiments of the semiconductor device,the germanium has a concentration within the shaping section of betweenabout 1% and about 10%.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A semiconductor device comprising: a finextending from a substrate; a source/drain region in the fin, thesource/drain region comprising: a bulk section comprising a firstsemiconductor material and a first dopant, a first interface of the bulksection and the fin having a first concentration of the first dopant; ashaping section on the bulk section, the shaping section comprising thefirst semiconductor material and the first dopant, a second interface ofthe shaping section and the bulk section having a second concentrationof the first dopant, the second concentration being greater than thefirst concentration; and a finishing section on the shaping section, thefinishing section comprising the first semiconductor material and thefirst dopant, a third interface of the finishing section and the shapingsection having a third concentration of the first dopant, the thirdconcentration being greater than the second concentration.
 2. Thesemiconductor device of claim 1, wherein the source/drain region has aheight to width ratio of between about 0.05 and about
 10. 3. Thesemiconductor device of claim 1, wherein the shaping section has athickness of between about 1 nm and about 50 nm.
 4. The semiconductordevice of claim 1, wherein the bulk section, the shaping section, andthe finishing section further comprise a second dopant.
 5. Thesemiconductor device of claim 4, wherein the first interface is freefrom the second dopant, the second interface has a fourth concentrationof the second dopant, and the third interface has a fifth concentrationof the second dopant, the fifth concentration being greater than thefourth concentration.
 6. The semiconductor device of claim 5, whereinthe second dopant is germanium.
 7. The semiconductor device of claim 1,wherein the first dopant is phosphorous.
 8. A semiconductor devicecomprising: a fin extending from a substrate; a source/drain region inthe fin, the source/drain region comprising: a bulk section comprising afirst semiconductor material and a first dopant, a first interface ofthe bulk section and the fin having a first concentration of the firstdopant; a shaping section on the bulk section, the shaping sectioncomprising the first semiconductor material and the first dopant, asecond interface of the shaping section and the bulk section having asecond concentration of the first dopant, the second concentration beinggreater than the first concentration; and a finishing section on theshaping section, the finishing section comprising the firstsemiconductor material and the first dopant, a third interface of thefinishing section and the shaping section having a third concentrationof the first dopant, the third concentration being greater than thesecond concentration, wherein the source/drain region has a height towidth ratio of between about 0.05 and about 10, wherein the shapingsection has a thickness of between about 1 nm and about 50 nm.
 9. Thesemiconductor device of claim 8, wherein the bulk section, the shapingsection, and the finishing section further comprise a second dopant. 10.The semiconductor device of claim 9, wherein the first interface is freefrom the second dopant, the second interface has a fourth concentrationof the second dopant, and the third interface has a fifth concentrationof the second dopant, the fifth concentration being greater than thefourth concentration.
 11. The semiconductor device of claim 10, whereinthe second dopant is germanium.
 12. The semiconductor device of claim 8,wherein the first dopant is phosphorous.
 13. A semiconductor devicecomprising: a fin extending from a substrate; a source/drain region inthe fin, the source/drain region comprising: a bulk section comprising afirst semiconductor material and a first dopant, a first interface ofthe bulk section and the fin having a first concentration of the firstdopant; a shaping section on the bulk section, the shaping sectioncomprising the first semiconductor material and the first dopant, asecond interface of the shaping section and the bulk section having asecond concentration of the first dopant, the second concentration beinggreater than the first concentration; and a finishing section on theshaping section, the finishing section comprising the firstsemiconductor material and the first dopant, a third interface of thefinishing section and the shaping section having a third concentrationof the first dopant, the third concentration being greater than thesecond concentration, wherein the bulk section, the shaping section, andthe finishing section further comprise a second dopant, wherein thefirst dopant is phosphorous, wherein the second dopant is germanium. 14.The semiconductor device of claim 13, wherein the source/drain regionhas a height to width ratio of between about 0.05 and about
 10. 15. Thesemiconductor device of claim 3, wherein the shaping section has athickness of between about 1 nm and about 50 nm.
 16. The semiconductordevice of claim 3, wherein the first interface is free from the seconddopant, the second interface has a fourth concentration of the seconddopant, and the third interface has a fifth concentration of the seconddopant, the fifth concentration being greater than the fourthconcentration.